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Phase II Final Report DVMCS P DOWNHOLE VIBRATION MONITORING & CONTROL SYSTEM FINAL REPORT – PHASE II Starting date: June 1, 2004 Ending Date: January 31, 2006 Principal Author: Martin E. Cobern Date Issued: April 30, 2006 DOE Award Number: DE-FC26-02NT41664 Submitting Organization APS Technology, Inc. 800 Corporate Row Cromwell, CT 06416 Phase II Final Report DVMCS p. 1 DISCLAIMER This report was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any informa- tion, apparatus, product, or process disclosed, or represents that its use would not in- fringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Govern- ment or any agency thereof. ABSTRACT The objective of this program is to develop a system to both monitor the vibration of a bottomhole assembly, and to adjust the properties of an active damper in response to these measured vibrations. Phase I of this program, which entailed modeling and de- sign of the necessary subsystems and design, manufacture and test of a full laboratory prototype, was completed on May 31, 2004. The principal objectives of Phase II were: more extensive laboratory testing, including the evaluation of different feedback algorithms for control of the damper; design and manufacture of a field prototype system; and, testing of the field prototype in drilling laboratories or test wells. The specific tasks were modified in November, 2005 and these tasks are used as the basis of organization for this report. The laboratory testing at TerraTek Laboratories was completed in January, 2006. These tests demonstrated that the DVMCS can maintain more consistent weight- on-bit, decrease vibration and increase the rate of penetration. With the exception of Task 10 (Ordering all long lead items for field prototypes), all of the tasks outlined have been completed and form the basis for the field testing and commercialization in Phase III, which is scheduled to end in January, 2007. Phase II Final Report DVMCS p. 2 Table of Contents Executive Summary..................................................................................................................... 4 Task 1: Develop final prototype development & testing plan...................................... 5 Task 2: Complete detailed design of prototype system using CAD........................... 5 Redesign of laboratory prototype .......................................................................................5 Design of feedback system .................................................................................................5 Intermediate prototype design ............................................................................................5 Task 3: Build mockups for laboratory testing................................................................. 6 Task 4: Test mockups in laboratory and analyze performance .................................. 6 Preliminary Tests & Analysis...............................................................................................6 Implications for Redesign ....................................................................................................7 Further testing with demagnetization.................................................................................7 Task 5: Redesign mockups based on test results ........................................................ 9 Task 6: Build revised mockup .......................................................................................... 9 Task 7: Retest mockups in laboratory and analyze performance ............................10 Task 8: Refit laboratory mockup for use in drilling laboratory...................................10 Task 9: Test in drilling laboratory...................................................................................13 Task 10: Complete procurement of long-lead items.....................................................14 Task 11: Update economic, market and environmental analyses..............................15 Economic & Market Analysis............................................................................................ 15 Environmental analysis ..................................................................................................... 15 Task 12: Update financing plan........................................................................................15 Task 13: Submit Phase II final report ..............................................................................16 Other ............................................................................................................................................18 Units .............................................................................................................................................18 References..................................................................................................................................18 Appendix A: Minimum WOB Variation....................................................................................19 Appendix B: Hardening Algorithm ...........................................................................................24 Appendix C: Magnetic Testing .................................................................................................30 Appendix D: MR Fluid Viscosity Testing ................................................................................37 Appendix E: Testing of DVMCS Prototype with Outer Coils ...............................................47 Scope.......................................................................................................................................48 Conclusions.............................................................................................................................48 Discussion...............................................................................................................................49 Outer Coil Results..................................................................................................................50 Original Inner Coil Results....................................................................................................53 Appendix F: Analysis of TerraTek Results.............................................................................54 Scope.......................................................................................................................................55 Conclusions.............................................................................................................................55 Recommendations .................................................................................................................56 Discussion...............................................................................................................................56 Appendix G: Final Design of Field Prototype.........................................................................69 Appendix H: Excerpt from Spears Market Study..................................................................71 Phase II Final Report DVMCS p. 3 Executive Summary The objective of this program is to develop a system to both monitor the vibration of a bottomhole assembly, and to adjust the properties of an active damper in response to these measured vibrations. Phase I of this program, which entailed modeling and de- sign of the necessary subsystems and design, manufacture and test of a full laboratory prototype, was completed on May 31, 2004. The principal objectives of Phase II were: more extensive laboratory testing, including the evaluation of different feedback algorithms for control of the damper; design and manufacture of a field prototype system; and, testing of the field prototype in drilling laboratories or test wells. The specific tasks were modified in November, 2005 and these tasks are used as the basis of organization for this report. The laboratory testing at TerraTek Laboratories was completed in January, 2006. These tests demonstrated that the DVMCS can maintain more consistent weight- on-bit, decrease vibration and increase the rate of penetration. With the exception of Task 10 (Ordering all long lead items for field prototypes), all of the tasks outlined have been completed and form the basis for the field testing and commercialization in Phase III, which is scheduled to end in January, 2007. Phase II Final Report DVMCS p. 4 Task 1: Develop final prototype development & testing plan This task was completed early in this Phase, and then modified slightly in November, 2005. The tasks below represent this revised plan. Task 2: Complete detailed design of prototype system using CAD Redesign of laboratory prototype The redesigned valve now has the coils located in the non-reciprocating portion of the tool. This lends itself to a more reliable electrical connection and better protection of the coils from the abrasive MR fluid. Design of feedback system The
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